WELL GOT NO PICS AT THE MOMENT BUT THE SHELL IS NOW STRIPPED COMPLETLY AS IS THE DOORS, BONNET BOOT IT'S NOW READY TO GO TO THE SHOTBLASTERS, I WON'T GET THAT DONE UNTILL THE END OF THE MONTH AS I GO ON HOLIDAY IN 2 WEEKS BUT WILL POST PICS WHEN IT HAS BEEN BLASTED THEN YOU CAN SEE ALL THE HOLES THAT WILL HAVE APPEARED. SOME BITS ARE ALREADY AT THE BLASTERS AXLE CASING. X-MEMBER SO SHOULD GET THEM BACK THIS WEEK ALL PRIMED IN 2 PACK.
GOT THE SHELL AND OTHER BITS BACK FROM THE BLASTERS TODAY. AS YOU'LL SEE I GOT A BIT OF WELDING TO DO
i663.photobucket.com/albums/uu356/JIM1845/TSY%20911%20POP/09040016.jpg[/img]WELL I DON'T THINK THERE IS AS MUCH WELDING
LET THE FUN BEGIN. :lol!:
GONNA START AT THE REAR END AND THE VALANCE
REMOVE THE VALANCE
AFTER I HAD DONE THIS AND LOOKED AT THE CHASSIS RAILS APART FROM BAD REPAIRS THEY ARE GETTING THIN
ALSO THE BOOT FLOOR NEEDS PANELS REPLACING AND THEY ARE FITTED BEFORE THE VALANCE
SO I HAVE CHOPPED THEM OFF.
I WILL REPLACE THEM AFTER I HAVE FITTED THE NEW PANELS IN THE FLOOR CUZ IT WILL BE EASIER. I WON'T BE NEEDING THE REAR SPRING HANGER MOUNTS EITHER AS I'M GOING 4 BAR LINK AND PANHARD ROD ROUTE
WELL I HAVE MADE A FEW PANELS BECAUSE ONE PANEL TIES IN WITH ANOTHER SO BEFOR I CAN FIT THE VALLANCE THIS HAS GOT TO BE DONE.
HERE IS THE NEW AND OLD INNER WING
JUST HERE
NEW BOOT FLOOR PANEL MADE
NOW WELDED UP AND A LITTLE BIT ADDED ON THE END
TRIAL FIT OF THE INNER WING
FLOOR CUT OUT READY FOR THE NEW PARTS
STARTING TO TACK IT UP, STILL HAVE A FEW MORE LITTLE BITS TO MAKE TO GET THIS SIDE COMPLETE BEFORE I CAN START THE OTHER AND GET THE VALANCE ON
I PAINT ALL MY PANELS THAT I MAKE TO STOP THEM FROM GOING RUSTY AND ANYWHERE I HAVE WELDED CUZ YOU NEVER KNOW WHEN YOU'LL GET BACK TO IT
[/img]
BOOT FLOOR SECTION WELDED IN AND GROUND UP,
NOW TO TIDY UP THE TOP EDGE
THIS BIT OF THE INNER WHEEL TUB WAS ROTTEN AND THIN SO OUT WITH THE OLD AND IN WITH THE NEW
THE NEW LIP VALLANCE LIP IN
NOW TO SORT OUT THE LOWER WING
MADE A NEW BIT AND TACKED IT IN
CLAMPED NEW BIT TO THE THE INNER WING PANEL WHICH IS ONLY CLAMPED ASWELL TO KEEP THE SHAPE. I WON'T WELD THE INNER PANEL IN TILL I HAVE TO CUS IT GIVES YOU A BIT MORE ROOM TO MOVE FOR GRINDING ETC. NOW TO THE LEADING EDGE OF THE ARCH AND WHEEL TUB
FIRST A NEW BIT IN THE TUB
NOW YOU CAN SEE WHY I AIN'T WELDED THE INNER WING IN. THEN TO THE WHEEL ARCH
I'M HAVING TO MAKE THIS IN BITS AND WELD IT TOGETHER DUE TO IT'S AWKWARD SHAPE
BUT ONCE FULLY WELDED AND GROUND UP IT WILL BE OK
NOW IT'S JUST A MATTER OF PUTTING IN THE LAST PANEL HAVING A RUB ROUND WITH THE GRINDER AND A COAT OF RED OXIDE TO STOP IT FROM RUSTING
JUST A SKIM OF FILLER NEEDED WHEN I GET TO THAT STAGE. WELDED A FEW TRIM HOLES ASWELL BECAUSE I WON'T BE HAVING ANY TRIM ON THIS CAR
NOW TO THE PASSENGER SIDE, FIRST SORT OUT THIS
THINK SOMEONE WAS GOING TO FIT THE EARLY LIGHTS, BUT OUT WITH THE WELDER
THERE ALL BETTER
HERE WE GO AGAIN , THIS IS THE PASSENGER REAR WING LOWER
I BOUGHT A NEW PANEL FROM EXPRESSED FOR THIS SIDE
MINE WASN'T ROTTEN ALL THE WAT TO THE TOP OF THIS PANEL SO I CUT IT DOWN
MARK AND CUT OFF THE ROT
BECAUSE I'M GOING TO BUTT WELD THIS IN I'M USING THE CLAMPS I GOT FROM FROST
GOT IT WELDED IN
NOW GROUND UP
AND A COAT OF PAINT
ONTO THE BOOT FLOOR
CUT THIS BIT OUT TO USE LATER
STARTED MAKING THE NEW FLOOR PANEL
NOT QUITE THE SAME BUT CLOSE
WELDED UP THE SLITS THAT I CREATED SO I COULD BEND THE PANEL
CUT OUT THE FLOOR
WELD ON THE TANK STRAP FIXING. NO IT'S NOT GUESS WORK I DID MEASURE IT BEFORE I TOOK IT OFF AND HAVE TRIAL FITTED THE FLOOR PANEL SO THE DIMENSIONS ARE CORRECT
NOW WELDED ON THE LITTLE INFILL BIT THAT I COULDN'T BEND WHILE DOING THE FLOOR PANEL
WELD THE FLOOR PANEL IN
GRIND OFF THE WELDS
ANOTHER STEP CLOSER TO COMPLETION
ONTO THE WHEEL TUB LIP
AND THE INNER ARCH
DONE AND PAINTED
STARTED MAKING THE INNER WING
ALL DONE. GAVE IT A COAT OF PAINT AND WELDED THE PETROL TANK SUPPORTS ON
NEW BITS WELDED IN
ALL GROUND AND PAINTED
FORGOT TO TAKE A COUPLE OF PICS BUT HERE IS THE INNER WING WELDED IN AND PAINTED
SO THATS THE FLOOR AND WING DONE NOW ON TO THE VALLANCE. FIRST WELD THE NEW BITS OF FLOOR BACK TO THE REAR PANEL
THE VALLANCE I HAVE BENT THE TABS BACK SO THEY SIT BEHIND THE REAR WING QUARTERS THEN WHEN I FINISH THE BODY I SHOULD HAVE A SMOOTH CORNER INSTAED OF THE LIP THAT STICKS OUT
LIKE THIS ALTHOUGH IT WILL STILL REQUIRE FILLER
AS YOU CAN SEE THE VALLANCE IS ON
NOW ALL THE BOOT FLOOR IS DONE I HAVE GOT TO MAKE 2 NEW CHASSIS RAILS AS THEY WERE BADLY REPAIRED AND STILL ROTTEN IN SOME PLACES. SO HERE WE GO I DO HAVE A BENDER BUT FOR THIS PARTICUALR JOB I DIDN'T USE IT
THIS IS ONE WAY OF DOING IT
TOOLS
TIN SNIPS - PLYERS - HAMMER - WELDER - GRINDER - VICE - DRILL
FIRST MAKE A TEMPLATE IN CARD TO GET THE SHAPE YOU NEED
ONCE YOU HAVE DONE THIS WRIGHT ON THE TEMPLATE WHERE YOU NEED TO ADD EXTRA FOR LIPS AND RETURNS, THE REASON FOR THIS AND NOT MAKING THE TEMPLATE BIGGER IS THAT YOU CAN USE IT FOR BOTH SIDES, AND YOU GET A MORE ACCURATE SHAPE.
NEXT YOU NEED TO DRAW IT ONTO STEEL AND CUT THEM OUT
AS YOU CAN SEE I HAVE ADDED THE EXTRA ON FOR A LIP AND AT THE END AS IT NEEDS TO FIT BEHIND THE VALLANCE TO PICK UP THE BUMPER MOUNTS. CUT OUT THE OTHER SIDE AND IF YOU ARE DOING BOTHE SIDES OF THE CAR THEN YOU'LL NEED 4
NEXT YOU NEED TO CUT A STRIP OF STEEL THE WIDTH OF THE CHASSIS RAIL AND THE LENGTH ON THE NEW SECTION YOU ARE GOING TO MAKE, I ALWAYS LEAVE THIS SLIGHTLY LONGER BETTER TO BE SAFE THAN SHORT
IT IS BEST AT THIS STAGE TO MARK THE SIDES UP LEFT AND RIGHT AS FROM HERE ON THEY WILL BE HANDED.
BECAUSE THESE HAVE A RADIUS I HAVE MADE SEVERAL CUTS UPTO THE LINE
SO NOW WE START TO BEND THE LIP, DO IT A BIT AT A TIME AS IT MAKES FOR A TIDIER JOB
ONCE YOU HAVE IT BENT TAP IT WITH A HAMMER ON THE CORNER OF THE VICE TO GET A TIGHT CORNER
FINALLY I BENT OVER THE TABS AT THE END IN THE VICE, SO NOW YOU SHOULD HAVE 2 PIECES LEFT AND RIGHT
NEXT TAKE THE STRIP AND LEVEL IT WITH THE END IT MIGHT BE EAISIER IF YOIU HAVE SOME ONE TO HOLD IT FOR YOU AND JUST PUT SOME SMALL TACKS ON THE EDGE AND WORK YOUR WAY ALONG
IT SHOULD END UP SOMETHING LIKE THIS
LOOK DOWN THE LENGTH AND MAKE SURE IT'S A RIGHT ANGLE, THEN DO THE SAME WITH THE OTHER SIDE
AGAIN LOOK DOWN THE LENGTH TO MAKE SURE IT'S SQUARE
NOW WELD IT TOGETHER ON THE INSIDE KEEP THE TACKS TO A MINIMUM AND SPREAD THEM OUT TO AVOID DISTORTION
ONCE DONE THEN FULLY WELD IT BETWEEN THE TACKS, IT WON'T LOOK PRETTY BUT NO ONE WILL SEE IT
AGAIN CHECK THAT IT'S SQUARE. NOW I HAVE WELDED UP THE CUTS I MADE SO I COULD BEND THE LIP
THEN I HAVE RUN A BEAD OF WELD DOWN THE JOINTS ON THE OUTSIDE SO I CAN GRIND IT UP AND HAVE A ROUND CORNER THAT WAY IT WILL MATCH THE ORIGINAL RAIL BETTER
NOW IT'S JUST GRIND IT UP, DON'T GRIND INSIDE THE CHANNEL AS THIS IS WHERE THE STRENGTH IS AND DON'T FORGET TO PAINT IT INSIDE TO PREVENT RUSTING. I HAVE DRILLED THE HOLES FOR THE SPOT WELDS AND THE BUMPER MOUNTS
THEN IF YOU NEED TO THEN MAKE ANOTHER FOR THE OTHER SIDE
NOW YOU CAN CUT OFF THE OLD RAIL IF YOU HAVN'T ALREADY DONE SO BUT IT'S BEST TO LEAVE IT TILL THIS STAGE AS YOU CAN THEN GET IT EXACTLY RIGHT BY USING THE NEW RAIL AS A TEMPLATE, THEN WELD THROUGH THE HOLES
I HAVE USED THE BOLTS IN THE BUMPER MOUNTS TO KEEP IT ALL IN PLACE AT THAT END WHILE I STARTED AT THE OTHER. ONCE DONE GRIND THE TOPS OFF THE SPOT WELDS AND PAINT
HOPE THIS HELPS SOME OF YOU OUT THERE
HERES A FEW MORE PICS OF THE CHASSIS RAILS
NOW ONTO THE BOOT GUTTER RAIL, I HAVE GOT A FEW AREAS TO DO BUT THIS IS THE FIRST BIT
MADE A NEW SECTION IN A SIMILAR WAY TO THE CHASSIS RAILS
GROUND UP AND PAINTED THE NEW PEICE WAS USED AS A TEMPLATE TO CUT OUT THE OLD BIT
SO NOW IT'S JUST TACK IN THE NEW SECTION TO MAKE SURE IT FITS WELL AND NEEDS NO MORE MODIFICATION
NOW I'M HAPPY WITH IT, FULLY WELDED IN AND GROUND UP
AND THEN A COAT OF PAINT, GOOD AS NEW
WELL I HAVE A FEW SECTIONS OF GUTTER RAIL AROUND THE BOOT TO DO I HAVE ALREADY DONE ONE BIT. THIS IS HOW TO MAKE A STRAIGHT SECTION CURVED ONES ARE THE SAME WAY AS THE CHASSIS RAILS.
THIS IS THE SECTION I'LL BE DOING
FIRST MEASURE HOW LONG THE REPAIR IS THEN MAKE A PLATE THAT LENGTH BY ABOUT A 1/12 WIDE, HE REASON FOR THIS WILL I WILL EXPLAIN LATER
MEASURE 5/32 FROM THE EDGE AND BEND IT TO 90 DEGREES
TAKE IT EASY AND DO IT A BIT AT A TIME AS THIS WILL BE THE SAFETY EDGE THAT YOU'LL SEE. AT THIS POINT I PAINT THE INSIDE WITH RED OXIDE AS WHEN IT IS BENT RIGHT OVER IF YOU DON'T THERE WILL BE NO RUST PROTECTION AND IT WILL RUST. ONCE DRY FOLD IT RIGHT OVER ON ITS SELF
I TAP IT ALONG THE EDGE WHILE RESTING ON THE FLAT OF THE VICE BECAUSE YOU CAN'T BEND IT ALL THE WAY UNLESS YOU HAVE ACCESS TO SHEET METAL MACHINERY. TRY TO KEEP IT EVEN AND A TIGHT JOINT LIKE THIS
ONCE TIGHT TURN IT OVER AND HAMMER THE OTHER SIDE TO TO EVEN IT UP AS IT DOES TWIST A BIT. THEN MEASURE 5/8 FROM THE OUTSIDE OF THE SAFETY EDGE AND UT OFF THE EXCESS. THIS IS THE REASON FOR LEAVING IT WIDER THAN NEEDED AS IT DON'T TEND TO DISTORT,
CUT ANOTHER STRIP THE SAME LENGTH AND 1 1/8 WIDE, MEASURE AND DRAW A FOLD LINE 1/2 FROM THE EDGE
BEND UP INTO A RIGHT ANGLE
NOW YOU HAVE THE BITS MADE THERE IS A LITTLE BENDING TO DO BEFORE YOU WELD IT TOGETHER, AS YOU CAN SEE MOST OF THE GUTTER RAIL IS NOT A STRAIGHT SECTION
HOLD THE SAFETY EGDED PIECE PIECE OVER TWO BITS OF WOOD AND ROLLED EDGE DOWN AND SOFTLY TAP WITH A HAMMER TILL YOU HAVE GOT THE SHAPE, IT WILL GO WITHOUT DISTORTING IT, BUT IF IT DOES THEN LAY IT ON A FLAT SURFACE AND TAP IT BACK
NOW YOU NEED TO BEND THE ANGLE PIECE TO THE SAME SHAPE, THE WAY TO DO THIS IS ON THE 5/8 PIECE OF THE ANGLE LAY IT ON A SMOOTH FLAT SURFACE AND START FROM THE MIDDLE OF WHERE YOU NEED TO BEND IT STRIKE IT FIRMLY WORKING YOUR WAY TO THE EDGE OF THE CURVE, THIS IS CALLED STRETCHING THE METAL, KEEP DOING THIS UNTILL IT IS THE SAME SHAPE AS THE FIRST PIECE THEN YOU CAN TACK THEM TOGETHER
CHECK THAT ITS ALL SQUARE AND THEN FULLY WELD IT
NOW GRIND IT ALL UP INSIDE AND OUT AS IT WILL BE EAISIER THE WHEN ITS ON THE CAR
NOW USE THE FINISHED SECTION AS YOUR TEMPLATE AND MARK WHERE YOU GOING TO CUT
CUT EITHER END AND DRILL OUT THE SPOT WELDS
ONEC REMOVED CLEAN UP THE AREA AND MAKE ANY REPAIRS, I THE PAINT WITH RED OXIDE AGAIN ON THE JOINING PARTS TO HELP PREVENT RUST
DRILL SOME HOLES IN THE EDGE FOR SPOT WELDS AND WELD IT IN
A GRIND AND A COAT OF PAINT JOBS DONE
WELL ON TO SOME MORE BOOT GUTTER, THIS IS THE PASSENGER SIDE
GOT IT CUT OUT
AND THE NEW PIECE IN
NOW A GRIND UP AND A COAT OF PAINT
NOW ON TO THE OTHER SIDE
AGAIN CUT IT OUT
AND WELD THE NEW SECTION IN
NOW ON TO THE LAST BIT
AGAIN CUT IT OUT AND IN WITH THE NEW SECTION
AND TO FINISH A GRIND UP AND PAINT